GB2104711A - Nuclear fuel element, and method of producing same - Google Patents

Nuclear fuel element, and method of producing same Download PDF

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Publication number
GB2104711A
GB2104711A GB08218232A GB8218232A GB2104711A GB 2104711 A GB2104711 A GB 2104711A GB 08218232 A GB08218232 A GB 08218232A GB 8218232 A GB8218232 A GB 8218232A GB 2104711 A GB2104711 A GB 2104711A
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Prior art keywords
fuel
zirconium
container
column
nuclear fuel
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GB08218232A
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GB2104711B (en
Inventor
Joseph Sam Armijo
Ernest Laurel Esch
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General Electric Co
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General Electric Co
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    • GPHYSICS
    • G21NUCLEAR PHYSICS; NUCLEAR ENGINEERING
    • G21CNUCLEAR REACTORS
    • G21C3/00Reactor fuel elements and their assemblies; Selection of substances for use as reactor fuel elements
    • G21C3/02Fuel elements
    • G21C3/04Constructional details
    • G21C3/16Details of the construction within the casing
    • G21C3/20Details of the construction within the casing with coating on fuel or on inside of casing; with non-active interlayer between casing and active material with multiple casings or multiple active layers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00Energy generation of nuclear origin
    • Y02E30/30Nuclear fission reactors

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Plasma & Fusion (AREA)
  • General Engineering & Computer Science (AREA)
  • High Energy & Nuclear Physics (AREA)
  • Monitoring And Testing Of Nuclear Reactors (AREA)
  • Structure Of Emergency Protection For Nuclear Reactors (AREA)
  • Laminated Bodies (AREA)
  • Glass Compositions (AREA)
  • Catalysts (AREA)

Abstract

An improved nuclear fuel element for use in the core of a nuclear reactor. The improved fuel element has a barrier bonded over the inside surface of the fuel container only in the section thereof adjacent to the charge of fissionable fuel material contained therein. A method of producing the fuel element is disclosed.

Description

SPECIFICATION Nuclear fuel element, and method of producing same This invention relates to an improvement in nuclear fuel elements for service in the core of nuclear fission reactors, and applies to such fuel elements having a composite container comprising a cladding sheath provided with a protective barrier covering the inner surface thereof.
Nuclear fuel elements having a composite container and to which this invention specifically relates are disclosed in U.S. Patent No.
4,200,492 and in pending application for patent Serial No. 14,348, filed February 23, 1979.
The disclosures of the aforesaid patent, No.
4,200,492, and of the publications cited therein, are all incorporated herein by reference.
Barrier layers or coatings bonded over the inside surface of nuclear fuel containers, commonly referred to as fuel cladding, are provided to protect the metal container from certain deleterious phenomena known as stress corrosion cracking and/or liquid metal embrittlement. The occurrence of such destructive activity results in failure of the unit.
The cause of this phenomena is generally attributed to a combination of mechanical and chemical interactions occurring between the nuclear fuel material, the metal container and the products of nuclear fission during reactor service.
For instance, neutrons and fission products from the fuel material irradiate and interact with the metal of the container while physical forces are applied thereto by the thermal expansion of the body of fuel. The failure of nuclear fuel elements from such causes is described in some detail in U.S. Patent Nos. 4,057,466 and 4,045,288, and elsewhere in the art.
Stress corrosion cracking and other destructive phenomena of zirconium alloy fuel containers, such as those constructed of the well known, commercially available Zircaloy compositions (see U.S. Patent No. 2,772,964), has been found to be effectively controlled or overcome by imposing a barrier of zirconium metal of at least moderate purity over the inside surface of the container.
This use of zirconium metal barriers for fuel containers is set forth in the above noted patent 4,200,492 and application S.N. 14,348.
Typical nuclear fuel elements for use in power generating nuclear reactors have fissionable fuel material in only a portion of the container or cladding sheath, whereby there remains a vacant region therein devoid of any fuel. The provided vacant region comprises a plenum or empty space within the fuel container for the accumulation and retention of gaseous fission products, water vapor and any other volatiles.
In this common type of nuclear fuel element, a column of fissionable fuel material, such as stacked pellets, is deposited within the container extending upward from its base or lower end. The quantity of fuel in the column is designed to extend therefrom to a pre-determined height or point within the container and the uppermost or remaining portion of the fuel container extending beyond the fuel charge is without fuel as illustrated in U.S. Patent Nos. 3,898,125 and 3,969,186, for example. The fuel element and its container is thus divided into a fuel portion and a plenum region at the interface boundary therebetween.
This plenum region within the fuel container in the area beyond the fuel charge therein, is provided with a biasing means such as a spring shown in the aforesaid patents to retain the fuel charge in position, such as affixed abutting one end of the container.
Typically the fuel container plenum region is filled with helium or a like inert gas as a nonreactive, effective heat transfer medium.
Accordingly, the fuel container in the area of the plenum region beyond the fuel charge is essentially isothermal, and remains at a substantially equal temperature with its surroundings comprising the coolant due to the effective heat transferring capacity and mobility of the gas medium therein. The fuel container in the portion retaining the fissionable fuel material therein, is maintained at a temperature gradient during power generation with respect to its surroundings comprising the coolant. Specifically, there is a temperature gradient extending from within the fuel charge or column outward with markedly dropping temperatures through the fuel container wall to the surrounding coolant.
In the operation of a water cooled and/or moderated nuclear reactor system the release of hydrogen from the dissociation of water within the coolant medium is an inherent phenomenon.
The hydrogen release is primarily attributable to the irradiating conditions and high temperature of the system, and the strong affinity between oxygen and the zirconium alloys which are commonly used to fabricate fuel containers or cladding.
It has been determined that within a reactor environment, or combination of conditions such as referred to above, the behavior of free hydrogen and its effects upon zirconium alloy fuel containers vary with respect to different temperature conditions. For instance, it appears that the hydrogen seeks lower temperature levels upon permeating zirconium alloys whereby different temperature gradients or levels of the fuel container cause the hydrogen to migrate in different patterns therein.
Thus, upon penetrating the zirconium alloy of the fuel container in the portion retaining the fissionable fuel material, and therefore wherein there is a pronounced temperature gradient, hydrogen has been found to concentrate and remain at or near the cooler outer portion of the cladding wall and it is dispersed inward therefrom in diminishing amounts.
On the other hand, the hydrogen upon contacting and penetrating the zirconium alloy of the fuel container in the portion thereof providing the plenum region which is essentially isothermal, has been found to exhibit a propensity to migrate and distribute uniformly through the zirconium cladding wall of a fuel container. However, when a zirconium alloy fuel container is enhanced with a barrier of zirconium metal bonded over the cladding's inner surface, such as described in the hereinbefore cited patent and pending application for patent, the inwardly migrating hydrogen has been found to concentrate in the inner zirconium metal barrier provided for the protection of the container from the interiorly generated fission products and the fuel expansion.
Accordingly, in such barrier-provided fuel containers it appears that the hydrogen migrating into and through the zirconium alloy container wall significantly accumulates and concentrates within the area of the container wall adjacent to its interface with the zirconium metal barrier thereon.
Such a concentration of hydrogen atoms accumulated within a limited portion of the cladding wall, particularly adjacent to the interface of the bond of the barrier layer to the container inner surface, is an undesirable effect of the composite fuel container structure, and under severe operating conditions could degrade the fuel performance.
This invention comprises means for improving composite constructed nuclear fuel containers comprising a barrier of zirconium metal overlying the inner surface of a zirconium alloy container such as described in U.S. Patent 4,200,492, and rendering fuel elements comprising the same more resistant to hydrogen accumulation in service. The invention specifically comprises removing substantially all zirconium metal of the barrier layer from within the approximate portion of the fuel container comprising or defining the plenum region therein. Thus, the protective barrier of zirconium metal is retained covering only the inner surface portion of the zirconium alloy fuel container in the area approximately adjacent to or immediately embracing the fissionable fuel material contained therein.
This invention attempts to provide an improved nuclear fuel element comprising a composite fuel container having a cladding sheath of zirconium alloy and a protective barrier therefore of zirconium metal.
This invention also attempts to provide a nuclear fuel element having a composite cladding sheath of zirconium alloy and zirconium metal barrier that resists the deleterious effects of free hydrogen, and thereby extends the service life of the fuel element.
This invention further attempts to provide a nuclear fuel element comprising a composite container of zirconium alloy with a zirconium metal barrier therein that increases the asfabricated gas plenum volume and resists subsequent plenum volume reduction attributable to the action of hydrogen forming zirconium hydride compounds therein.
This invention in addition attempts to provide a method of improving nuclear fuel elements comprising a composite container of zirconium alloy with a zirconium metal barrier therein.
This invention also attempts to provide a method of rendering nuclear fuel elements comprising a component container of a zirconium alloy with a protective barrier of zirconium metal therein more resistant to free hydrogen and the debilitating effects thereof upon such fuel containers and their service life.
The present invention will be further described, by way of example only, with reference to the accompanying drawing, in which the figure of the drawing comprises a partial sectional view of a nuclear fuel element assembly containing fissionable fuel material constructed according to this invention.
This invention is particularly directed to nuclear fuel elements for power generating reactors having composite fuel containers comprising a cladding sheath of an alloy of zirconium such as a Zircaloy, with a protective covering barrier of substantially pure zirconium metal metallurgically bonded over inside surface. Nuclear fuel elements of this construction and composition are disclosed in U.S. Patent 4,200,492 and application Serial No. 1 4,348 noted hereinbefore.
Specifically, the invention deals with composite fuel containers constructed of a cladding sheath from a zirconium alloy having at least about 5O00 parts per million by weight of constituents therein other than zirconium, and a protective barrier member therefor of a zirconium metal having less than about 5000 parts per million by weight of impurities therein. Preferably the zirconium metal of the barrier component has less than about 4200 parts per million by weight of impurities. Alloys of zirconium for the fuel cladding sheath commonly comprise commercially available Zircaloy 2 or 4 which are well known in the nuclear industry.
This invention broadly comprises precluding any degrading or deleterious effects of free hydrogen upon composite nuclear fuel containers of the aforementioned design. Hydrogen caused degradation or impairment is overcome by removing the zirconium metal barrier material from within the zirconium alloy cladding sheath in the portion extending beyond the fuel charge whereby it is devoid of fissionable fuel material and comprises the plenum region.
The resultant unique fuel container of the novel nuclear fuel element of the invention resists hydriding in and about the plenum region which is free of any fuel material. Thus it avoids any discernable reduction in the void volume of the plenum area of the container provided for gas collection, attributable to the action of hydrogen reacting with zirconium metal to produce zirconium hydrides within the plenum region.
Removal of the zirconium metal of the barrier bonded on to the inside surface of the zirconium alloy cladding in the designated area of the plenum region can be accomplished by any one of several techniques or measures, or combinations thereof.
For instance, the zirconium metal can be eliminated by mechanical means such as abrading, reaming or honing. The mechanical removal can be effective with a tool of suitable dimensions to remove the zirconium metal from the surface of the alloy over an area generally coextensive with the section of the fuel container designed as the plenum region of the unit. Apt chemical means can also be used to remove the zirconium metal by contacting the section thereof designated for elimination of the zirconium metal with a dissoluting reagent such as an acid reactive with the metal.
Referring to the drawing, the improved nuclear fuel element 10 of the invention is constructed as follows. Fuel element 10 includes a closed, elongated composite container 12 comprising a cladding sheath 14 formed of an alloy of zirconium for the enclosure of the fissionable fuel material 1 6 and its physical isolation from the coolant medium (not shown) which surrounds the element 10 in service. Generally the fuel element 10 is tubular in configuration as illustrated. The container 12 includes closing end plugs affixed in ends of the tubular cladding sheath 14 to seal the container.
Fissionable fuel material 16, such as an oxide or other compound of uranium, plutonium or thorium, is commonly employed in the form of a plurality of small bodies such as the cylindrical shaped pellets shown. The fuel material 16, or units thereof, is generally of the same or similar cross-sectional configuration as the fuel container or sheath, typically cylindrical. Moreover, the body of the fuel material charge if of slightly smaller cross-sectioned area or dimension than the inside open area of the composite fuel container 12 to provide a free space 1 8 between the fuel and container for the purpose of enabling a predetermined unrestricted lateral thermal expansion of the fuel material 1 6.Thus, in a typical tubular fuel element, the cylindrical fuel charge provided therein would be of sufficiently smaller diameter with respect to the inside of the container to leave an annular space thereabout.
The fuel material 16, shown in pellet form, is stacked in a column extending upward from the base or lower end of the composite container 12 to the extent for providing therein a predetermined quantity of fissionable material for the fuel charge, which only partially occupies the interior space of the container 12. Typically in a water cooled and moderated power generating reactor the fuel charge would occupy the major portion of the volume of the container, or the length of a tubular element.
The remaining portion or length of the fuel container 12 extending beyond the fuel charge contained therein, is retained vacant or devoid of any solid fuel material to thereby provide a plenum region for the accumulation and retention of gaseous fission products, water vapor and the like free volatiles. In practice the plenum region is generally filled with an inert gaseous medium of good heat transferring characteristic such as helium to occupy the area and improve the efficiency of heat transfer without contributing to chemical activity. This minor portion of the fuel element comprising the plenum comprises only a small fraction thereof.For instance about 8 to 12 inches, preferably 10 inches, for a 1 60 inch long (150 inches of fuel) boiling water reactor fuel element, and about 4 to 8 inches, preferably 6 inches, in a pressure water reactor fuel element.
The column of the fuel charge within the container 1 2 is typically affixed in position with a spring 20 located within the plenum region as shown.
The fuel container 1 2 is thus divided by its contents and/or function into two distinct segments or portions, a fuel material retaining portion 22 and the plenum region 24.
In accordance with this invention the improved nuclear fuel element 10 has a protective barrier 26 of substantially pure zirconium metal superimposed continuously over and metallurgically bonded to the inside surface of the container cladding sheath 14 throughout the fuel retaining portion 22. Thus, the zirconium metal barrier 26 provides a lining on the inner surface of the container 12 in all portions thereof approximately adjacent to or embracing the body of the fuel material 16 retained therein.
In a preferred embodiment of this invention, the improved nuclear fuel element 10 is produced from a composite fuel container initially having a metallurgically bonded barrier of zirconium metal extending substantially over the entire interior surface thereof. The new fuel element is therefore formed by substantially completely removing the zirconium metal of the barrier member 26 from within the portion thereof to provide the plenum area that extends beyond the portion adjacent the fuel charge. A honing tool of apt dimensions and length to eliminate the zirconium metal layer down to the inside diameter of the underlying alloy and for a distance to the predetermined portion for the containment of the fuel charge, is preferred for this operation. Thus it can be achieved by means of a simple machining operation.
The zirconium metal of the barrier member 26 should be eliminated only in the portion of the fuel container designed to constitute the plenum region 24, and not beyond the approximate boundary between the plenum region and the fuel portion of the container which is approximately adjacent to fuel charge as shown in the drawing.
The boundary between the plenum region and fuel portion within the container preferably is designated at the approximate position of the fuel-plenum interface when the column of fuel material is a fully extended condition within the container is in a fully extended condition within the container as a result of the thermal expansion incurred under reactor service conditions.
However, precision of location of the fuel-plenum interface, and in turn elimination of the zirconium metal barrier, is not particularly critical, especially in boiling water reactors.
This is in part so because of the reduced fission activity, and in turn heat generated, in the upper portion of the fuel column and fuel element. The lower fission activity occurs in such upper regions because the steam produced displaces the water which functions as a neutron moderator. Thus the thermal gradient is not as great in the upper region of the fuel portion of the element as it is in the lower region thereof.

Claims (14)

Claims
1. A nuclear fuel element comprising a closed elongated container comprising a cladding sheath formed of an alloy of zirconium, a column of nuclear fuel material having a cross-section dimension smaller than the interior of the container disposed in and partially filling said container so as to leave a space thereabout between said fuel column and the interior of the container and to provide a plenum region within the container extending beyond the fuel column therein, said cladding sheath having a protective barrier of zirconium metal lining only the portion of its inner surface approximately adjacent to the column of fuel therein.
2. A nuclear fuel element as claimed in claim 1, whereby said column of fuel partially filling the container defines a fuel section in the portion adjacent thereto and a plenum region extending therebeyond, said cladding sheath having a protective barrier of zirconium metal lining covering only the portion of its inner surface in the fuel section thereof approximately adjacent to the column of fuel therein.
3. A nuclear fuel element as claimed in claim 1, wherein the nuclear fuel material is a column of pellets whereby said column of fuel partially filling the container defines a fuel section in the portion adjacent thereto and a plenum region extending therebeyond, said cladding sheath having a protective barrier of a zirconium metal lining covering the portion of its inner surface within the fuel section thereof approximately adjacent to the column of fuel therein, and the inner surface of the portion of the cladding sheath extending beyond the column of fuel forming the plenum region being substantially devoid of any zirconium metal of the protective barrier.
4. A nuclear fuel element as claimed in claim 1, wherein the nuclear fuel is a column of cylindrical pellets of nuclear fuel material having a diameter smaller than the interior diameter of the tubular container disposed on and partially filling said container so as to leave an annular space thereabout between said column of fuel pellets and the interior of the container and to provide a plenum region within the container extending beyond the column of fuel pellets whereby said column of fuel pellets partially filling the container defines a fuel section in the portion of the container adjacent thereto and a plenum region extending therebeyond, said cladding sheath having a protective barrier of zirconium metal lining covering the portion of its inner surface within the fuel section thereof approximately adjacent to the column of fuel pellets therein, and the inner surface of the portion of the cladding sheath extending beyond the column of fuel pellets forming the plenum region being substantially devoid of any zirconium metal of the protective barrier.
5. The nuclear fuel element as claimed in any one of the preceding claims wherein the nuclear fuel material is uranium, plutonium, thorium, or a mixture thereof.
6. The nuclear fuel element as claimed in any one of the preceding claims wherein the protective barrier is of substantially pure zirconium metal and is sponge zirconium or crystal bar zirconium.
7. A method of producing a nuclear fuel element having a composite container comprising a cladding sheath of an alloy of zirconium and a protective barrier of zirconium metal metallurgically bonded to the inside surface of said alloy cladding sheath, comprising the step of removing the zirconium metal of the barrier from the inside surface of the zirconium alloy cladding within the portion thereof to provide the plenum region extending from beyond the approximately upper most extent of nuclear fuel material to be provided therein for reactor service.
8. A method of producing nuclear fuel element having a composite container comprising a cladding sheath of an alloy of zirconium and a protective barrier of zirconium metal metallurgically bonded to the inside surface of said alloy cladding sheath, comprising the steps of removing the zirconium metal of the barrier from the inside surface of a segment of the zirconium alloy cladding and then introducing nuclear fuel into a segment of the zirconium alloy cladding having the protective barrier of zirconium metal retained therein.
9. A method as claimed in claim 7 or claim 8, wherein the zirconium metal of the barrier is removed from the segment of the alloy cladding by mechanical means.
10. A method as claimed in any one of claims 7 to 9, wherein the zirconium metal of the barrier is removed from the segment of the alloy cladding by honing.
11. An elongated container for a nuclear fuel element comprising a cladding sheath formed of an alloy of zirconium, said cladding sheath having a protective barrier of zirconium metal lining a major portion of the length of its inner surface and a minor portion of the length of its inner surface being substantially devoid of any zirconium metal.
12. The elongated container of claim 11, wherein the protective barrier is of substantially pure zirconium metal and is sponge zirconium or crystal bar zirconium.
1 3. An elongated tubular container for nuclear fuel element comprising a cladding sheath formed of an alloy of zirconium, said cladding sheath having a protective barrier of substantially pure zirconium metal and in sponge zirconium or crystal bar zirconium covering a major portion of the length of its inner surface comprising the approximate portion therein that will be adjacent to the fuel when charged therewith, and a minor portion of the length of the inner surface including the approximate portion therein that will comprise the plenum region being substantially devoid of any zirconium metal.
14. The elongated tubular container as claimed in any one of claims 11 to 13, wherein the protective barrier of zirconium metal covers at least about 90 percent of the length of the inner surface of the cladding sheath while less than about 10 percent of the length of the inner surface thereof is substantially devoid of any zirconium metal.
1 5. A nuclear fuel element as claimed in claim 1 , substantially as hereinbefore described, with reference to and as illustrated in the accompanying drawing.
1 6. A method of producing a nuclear element as claimed in claim 7 or claim 8, substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.
1 7. A nuclear fuel container as claimed in claim 11, substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.
GB08218232A 1981-08-24 1982-06-23 Nuclear fuel element and method of producing same Expired GB2104711B (en)

Applications Claiming Priority (1)

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US29575781A 1981-08-24 1981-08-24

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GB2104711B GB2104711B (en) 1985-05-09

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BE (1) BE894171A (en)
CA (1) CA1205927A (en)
DE (1) DE3226403A1 (en)
ES (1) ES279692Y (en)
FR (1) FR2511803B1 (en)
GB (1) GB2104711B (en)
IT (1) IT8222715A0 (en)
SE (1) SE451415B (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4775508A (en) * 1985-03-08 1988-10-04 Westinghouse Electric Corp. Zirconium alloy fuel cladding resistant to PCI crack propagation
US4933136A (en) * 1985-03-08 1990-06-12 Westinghouse Electric Corp. Water reactor fuel cladding

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SE509382C2 (en) * 1996-02-23 1999-01-18 Asea Atom Ab Component designed for use in a light water reactor and process for making such a component
US6512806B2 (en) 1996-02-23 2003-01-28 Westinghouse Atom Ab Component designed for use in a light water reactor, and a method for the manufacture of such a component
US20140169516A1 (en) * 2012-12-14 2014-06-19 Global Nuclear Fuel - Americas, Llc Fuel rods with varying axial characteristics and nuclear fuel assemblies including the same

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US2772964A (en) * 1954-03-15 1956-12-04 Westinghouse Electric Corp Zirconium alloys
US3085059A (en) * 1958-10-02 1963-04-09 Gen Motors Corp Fuel element for nuclear reactors
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Cited By (2)

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Publication number Priority date Publication date Assignee Title
US4775508A (en) * 1985-03-08 1988-10-04 Westinghouse Electric Corp. Zirconium alloy fuel cladding resistant to PCI crack propagation
US4933136A (en) * 1985-03-08 1990-06-12 Westinghouse Electric Corp. Water reactor fuel cladding

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SE8204812D0 (en) 1982-08-23
FR2511803A1 (en) 1983-02-25
DE3226403A1 (en) 1983-03-10
GB2104711B (en) 1985-05-09
BE894171A (en) 1983-02-23
FR2511803B1 (en) 1986-01-10
ES279692U (en) 1984-11-16
ES279692Y (en) 1985-06-01
JPH0136915B2 (en) 1989-08-03
IT8222715A0 (en) 1982-08-03
JPS5866093A (en) 1983-04-20
SE8204812L (en) 1983-02-25
CA1205927A (en) 1986-06-10
SE451415B (en) 1987-10-05
DE3226403C2 (en) 1987-07-16

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Effective date: 19970623